Surgical instrument and cartridge for use therewith

ABSTRACT

A cartridge assembly is disclosed. The cartridge assembly comprises a cartridge housing and a cartridge. The cartridge housing has a plurality of biasing members thereon. The cartridge is configured for reception at least partially within the cartridge housing. The cartridge includes a plurality of fasteners at least partially therein. The cartridge has a plurality of pockets. Each fastener is ejectable from a corresponding pocket. The cartridge has a plurality of chambers, and each chamber is adjacent a pocket and configured to store at least one fastener at least partially therein. At least one fastener is movable from the chamber to the pocket. The cartridge includes a plurality of pushers, where each pusher is configured to engage at least one corresponding fastener. At least one pusher includes at least one cam surface thereon. Each biasing member urges at least one corresponding fastener toward the corresponding pocket.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 13/173,295 filed Jun. 30, 2011, now U.S. Pat. No. 8,763,876, and the disclosures of each of the above-identified applications are hereby incorporated by reference in their entirety.

BACKGROUND

1. Technical Field

The present disclosure relates generally to instruments for surgically joining tissue and, more specifically, to a surgical instrument that can be fired more than once without being required to reload fasteners.

2. Background of Related Art

Various types of surgical instruments used to surgically join tissue are known in the art, and are commonly used, for example, for closure of tissue or organs in transection, resection, anastomoses, for occlusion of organs in thoracic and abdominal procedures, and for electrosurgically fusing or sealing tissue.

One example of such a surgical instrument is a surgical stapling instrument, which may include an anvil assembly, a cartridge assembly for supporting an array of surgical fasteners, an approximation mechanism for approximating the cartridge and anvil assemblies, and a firing mechanism for ejecting the surgical fasteners from the cartridge assembly.

Using a surgical instrument, it is common for a surgeon to approximate the anvil and cartridge members. Next, the surgeon can fire the instrument to emplace fasteners in tissue. Additionally, the surgeon may use the same instrument or a separate instrument to cut the tissue adjacent or between the row(s) of fasteners.

Additionally, a single use loading (“SULU”) or a disposable loading unit (“DLU”) may be attached to an elongated or endoscopic portion of a surgical stapling instrument. Such loading units allow surgical stapling instruments to have greater versatility, for example. The loading units may be configured for a single use, and/or may be configured to be used more than once.

Further, surgical instruments and/or loading units may include a cartridge that is removable and replaceable. For example, after all of the fasteners in a first cartridge have been ejected, a user may remove the first cartridge and replace it with a second cartridge including fasteners.

SUMMARY

The present disclosure relates to a cartridge assembly for use with a surgical instrument. The cartridge assembly comprises a cartridge housing and a cartridge. The cartridge housing has a plurality of biasing members thereon. The cartridge is configured for reception at least partially within the cartridge housing. The cartridge includes a plurality of fasteners at least partially therein. The cartridge has a plurality of pockets. Each fastener is ejectable from a corresponding pocket. The cartridge has a plurality of chambers therein, and each chamber is adjacent a pocket and is configured to store at least one fastener at least partially therein. At least one fastener is movable from the chamber to the pocket. The cartridge includes a plurality of pushers, where each pusher is configured to engage at least one corresponding fastener. At least one pusher includes at least one cam surface thereon. Each biasing member urges at least one corresponding fastener toward the corresponding pocket.

The present disclosure also relates to a loading unit configured for engagement with a surgical instrument. The loading unit comprising a proximal body portion defining a longitudinal axis, a tool assembly disposed in mechanical cooperation with the proximal body portion, and a cartridge assembly disposed in mechanical cooperation with the tool assembly. The cartridge assembly comprises a cartridge housing, a cartridge, and a driver. The cartridge housing has a plurality of biasing members thereon. The cartridge is configured for reception at least partially within the cartridge housing and includes a plurality of fasteners at least partially therein. The cartridge has a plurality of pockets, with each fastener being ejectable from a corresponding pocket. The cartridge has a plurality of chambers therein, and each chamber is adjacent a pocket and is configured to store at least one fastener at least partially therein. At least one fastener is movable from the chamber to the pocket. The cartridge also includes a plurality of pushers, and each pusher is configured to engage a corresponding fastener. Each biasing member urges at least one corresponding fastener toward the corresponding pocket. The driver is disposed in mechanical cooperation with the cartridge assembly, and is movable substantially parallel to the longitudinal axis into engagement with the pushers.

The present disclosure also relates to a surgical instrument comprising a handle assembly, a firing rod, an endoscopic portion, and a cartridge assembly. The handle assembly includes a movable handle. The firing rod is disposed in mechanical cooperation with the movable handle. The endoscopic portion extends distally from the handle assembly. The cartridge assembly is disposed adjacent a distal end of the endoscopic portion and comprises a cartridge housing, a cartridge, and a plurality of pushers. The cartridge housing has a plurality of biasing members. The cartridge is configured for reception at least partially within the cartridge housing. The cartridge includes a plurality of fasteners at least partially therein. The cartridge has a plurality of pockets. Each fastener is ejectable from a corresponding pocket. The cartridge has a plurality of chambers therein, and each chamber is adjacent a pocket and is configured to store at least one fastener at least partially therein. At least one fastener is movable from the chamber to the corresponding pocket. Each of the plurality of pushers is configured to engage a corresponding fastener. Each biasing member urges at least one corresponding fastener toward the corresponding pocket. Distal advancement of the firing rod causes sequential ejection of at least some of the fasteners.

The present disclosure also relates to a surgical stapling instrument comprising a cartridge assembly and an anvil assembly. The cartridge assembly has a cartridge body, a plurality of pushers supporting a plurality of fasteners in the cartridge body, and a driver longitudinally movable through the cartridge body in distal and proximal directions. The pushers have first cam surfaces and second cam surfaces. The anvil assembly has fastener forming surfaces. The driver has an upper portion and a lower portion. The upper portion of the driver contacts the second cam surfaces sequentially when the driver is moved in the proximal direction. The lower portion of driver contacts the first cam surfaces when the driver is moved in the distal direction.

BRIEF DESCRIPTION OF FIGURES

Various embodiments of the presently disclosed surgical instruments and loading units are disclosed herein with reference to the drawings, wherein:

FIG. 1A is a perspective view of a surgical instrument in accordance with the present disclosure;

FIG. 1B is a perspective view of another surgical instrument in accordance with the present disclosure;

FIG. 2 is a perspective view of a handle portion of the stapling instruments of FIGS. 1A and 1B;

FIG. 3 is a perspective view of a distal portion of the handle portion of FIG. 2;

FIG. 4 is a perspective view of a loading unit of the surgical instruments of FIGS. 1A and 1B;

FIG. 5 is a perspective exploded view of a clamping member and drivers of the surgical instruments of FIGS. 1A and 1B;

FIG. 6 is a perspective view of a portion of a cartridge assembly of the surgical instrument of the present disclosure;

FIG. 7 is a perspective view of a portion of a cartridge housing of the cartridge assembly of FIG. 6;

FIG. 8 is a perspective view of a portion of a cartridge, a plate and fasteners of the cartridge assembly of FIG. 6;

FIG. 9 is a perspective view of a pusher and fasteners of the cartridge assembly of FIG. 6;

FIG. 10 is a transverse cross-sectional view of a portion of the cartridge assembly of FIG. 6 including a plurality of fasteners therein;

FIG. 11 is a transverse cross-sectional view of a portion of the cartridge assembly of FIG. 6 including no fasteners therein;

FIG. 12 is a perspective view of a portion of a driver of FIG. 5;

FIG. 13 is a longitudinal cross-sectional view of a portion of the cartridge assembly of FIG. 6 in combination with a portion of a driver; and

FIG. 14 is a transverse cross-sectional view of a tool assembly, including an anvil and a cartridge channel, and including two cartridge assemblies, two drivers, and the clamping member.

DETAILED DESCRIPTION

Embodiments of the presently disclosed surgical instrument, loading unit for use therewith, and cartridge assembly for use therewith, are described in detail with reference to the drawings, wherein like reference numerals designate corresponding elements in each of the several views. As is common in the art, the term “proximal” refers to that part or component closer to the user or operator, e.g., surgeon or physician, while the term “distal” refers to that part or component farther away from the user.

A surgical instrument having linear jaw members of the present disclosure is indicated as reference numeral 100 a in FIG. 1A. A surgical instrument having curved jaw members of the present disclosure is indicated as reference numeral 100 b in FIG. 1B. Collectively, surgical instruments 100 a and 100 b are referred to herein as reference numeral 100. Similarly, several features that are common to both surgical stapling instruments 100 a and 100 b are collectively referred to as the same reference number (e.g., handle portion 110, endoscopic portion 120, and jaw members 230).

Handle portion 110 of surgical instrument 100 is shown in FIG. 2, and an enlarged view of the distal end of handle portion 110, including a distal end of firing rod 130, is shown in FIG. 3. A single use loading unit (“SULU”) or a disposable loading unit (“DLU”) (collectively referred to as “loading unit 200”), which is mechanically engageable with handle portion 100 is shown in FIG. 4. Loading unit 200 is attachable to endoscopic portion 120 of surgical stapling instrument 100, e.g., to allow surgical instrument 100 to have greater versatility. Loading unit 200 may be configured for a single use, and/or may be configured to be used more than once. Alternatively, a surgical instrument may have a cartridge which is removable and replaceable in the reusable jaws of the instrument.

Examples of loading units for use with a surgical stapling instrument are disclosed in commonly-owned U.S. Pat. No. 5,752,644 to Bolanos et al., the entire contents of which are hereby incorporated by reference herein. Further details of an endoscopic surgical stapling instrument are described in detail in commonly-owned U.S. Pat. No. 6,953,139 to Milliman et al., the entire contents of which are hereby incorporated by reference herein.

In a surgical instrument 100 in accordance with the present disclosure, a firing rod 130 is moved distally through actuation of a movable handle 132 to deploy the fasteners. For example, referring back to FIGS. 1A and 1B, at least a partial actuation of movable handle 132 with respect a stationary handle 134 translates firing rod 130 longitudinally, such that a dynamic clamping member 240, its associated bar 250, and a proximal block 260 (e.g., FIG. 5) translates longitudinally, to approximate at least one jaw member with respect to the other. It is also envisioned that other types of handles can be used such as, for example, motor-driven, hydraulic, ratcheting, etc.

In the embodiment illustrated in FIG. 14, dynamic clamping member 240 includes an I-shaped cross-section, the top portion of which is configured to engage the anvil assembly, and the bottom portion of which is configured to engage the cartridge assembly. More particularly, engagement between the top portion of the dynamic clamping member 240 and the anvil assembly causes the anvil assembly to pivot towards the cartridge assembly, e.g., to clamp tissue therebetween. Continued distal translation of the dynamic clamping member 240 helps maintain the relative positions of the cartridge assembly and the anvil assembly with respect to each other.

Additionally, upon distal advancement, dynamic clamping member 240 advances drivers 820 through cartridge assembly 222. As the drivers 820 move distally, each driver 820 sequentially engages a plurality of pushers, and causes the pushers to move vertically within the cartridge assembly and eject fasteners 760 towards the anvil. The dynamic clamping member 240 may include a cutting edge 242 on a distal face of dynamic clamping member 240 to sever the stapled tissue. Subsequent to the ejection of fasteners 760, the stapled tissue is cut by the cutting edge 242 of the dynamic clamping member 240.

With reference to FIG. 4, loading unit 200 of the present disclosure is shown. Loading unit 200 includes a proximal body portion 210 defining a longitudinal axis “A-A,” and a tool assembly 220 including a pair of jaw members 230. Proximal body portion 210 is configured to removably attach to endoscopic portion 120 of surgical instrument 100. More particularly, an insertion tip 202 of loading unit 200 is linearly inserted into the distal end of endoscopic portion 120 (FIGS. 2 and 3) of surgical stapling instrument 100. Nubs 204 of insertion tip 202 (FIG. 4) move linearly through slots (not shown) formed in the distal end of endoscopic portion 120. Subsequently, loading unit 200 is rotated about the longitudinal axis “A-A” such that nubs 204 move transversely through slots (not shown) within endoscopic portion 120. Additionally, during engagement of loading unit 200 and endoscopic portion 120, firing rod 130 of handle portion 110 engages dynamic clamping member 240 of loading unit 200 (see FIG. 5).

With reference to FIGS. 6-14, jaw members 230 of loading unit 200 include an anvil assembly 600 and a cartridge channel 700. In the illustrated embodiments, cartridge channel 700 houses a first cartridge assembly 710 a and a second cartridge assembly 710 b (collectively referred to as cartridge assembly 710), and includes a track 712 therebetween. Each cartridge assembly 710 includes a cartridge housing 720, a cartridge or cartridge body 740, a plurality of fasteners 760, a plurality of plates 780, and a plurality of pushers 800.

With particular reference to FIG. 7, each cartridge assembly 710 a, 710 b has a cartridge housing 720. One such cartridge housing 720 is shown. Cartridge housing 720 includes a plurality of biasing members 722 (e.g., leaf springs) thereon. Biasing members 722 are flexible fingers disposed on each side of the cartridge housing 710 and that are biased towards opposite side cartridge housing 720 (as shown in FIG. 7). Biasing members 722 are configured such that they are able to be against their bias into substantial alignment with an external wall 724 of cartridge housing 720 (see, for example, FIG. 10). As discussed below, each biasing member 722 is configured to bias a plate, and corresponding fasteners toward the opposite side of cartridge housing 720.

Referring now to FIGS. 8-11, cartridge or cartridge body 740, and components thereof, are illustrated. Cartridge or cartridge body 740 is configured for reception at least partially within cartridge housing 720 (FIG. 7) (e.g., a snap-fit connection) and includes a plurality of pockets 742, and a plurality of chambers 744 (FIG. 11). Each pocket 742 extends through a tissue-contacting surface 750 of cartridge body 740, and is configured to releasably store a fastener 760 that is ready to be fired. Each chamber 744 is adjacent a corresponding pocket 742 and is configured to store fasteners 760 therein (e.g., two fasteners 760). The configuration of pockets 742 and chambers 744 allows fasteners to move from chamber 744 to pocket 742 in response to the biasing force supplied by biasing members 722. An internal wall 746 of cartridge body 740 is adjacent pockets 742 and resists the biasing force, such that fasteners 760 do not get pushed beyond pocket 742.

With reference to FIGS. 6, 8, 10 and 11, plurality of plates 780 are shown. Plates 780 are disposed on the opposite side of chamber 744 than pockets 742. When fasteners 760 are present in cartridge body 740 (see FIG. 10), each plate 780 is between biasing member 722 and fastener 760. When no fasteners 760 are present in cartridge body 740 (e.g., after each fastener 760 has been fired; see FIG. 11), each plate 780 is between biasing member 722 and internal wall 746 (e.g., at least partially within pocket 742). Additionally, when no fasteners 760 are present in cartridge body 740, plates 780 block the path for advancement of pushers 800, thus preventing a user from firing/attempting to fire with an empty cartridge body 740. Plates 780 are sized to facilitate sliding within chamber 744 toward pocket 742. Additionally, and as shown in the embodiment illustrated in FIG. 8, plates 780 include a cut-out portion or indentation 782, which is sized to facilitate engagement with biasing member 722.

With particular reference to FIGS. 9-13, a plurality of pushers 800 and a plurality of fasteners 760 are shown. Each pusher 800 includes a central portion 802 and a pair of lateral portions 804 a, 804 b. Central portion 802 includes a first cam surface 806 and a second cam surface 808. As discussed below, each cam surface 806, 808 is configured to be engaged by a driver 820 to move pusher 800 toward and away from tissue-contacting surface 750 of cartridge body 740. Each lateral portions 804 a, 804 b is configured to engage a fastener 760, such that movement of pusher 800 toward tissue-contacting surface 750 of cartridge body 740 causes corresponding fasteners 760 to be ejected from cartridge body 740. In the illustrated embodiments, an upper surface 805 of lateral portions 804 includes a groove thereon (see FIGS. 9 and 10) to facilitate engagement with fastener 760.

Referring now to FIGS. 12-14 driver 820 is shown. Driver 820 is an elongated member that is configured to move longitudinally through a passage 741 (FIGS. 10 and 11) in cartridge body 740 in response to actuation of movable handle 132, for example. Driver 820 includes a slot 822 therein which separates an upper portion 823 from a lower portion 825. The slot 822 which extends proximally from a location adjacent a distal end thereof. Slot 822 includes a firing cam surface 824 and a retraction cam surface 826. Upon distal advancement of driver 820, firing cam surface 824 contacts first cam surface 806 of pusher 800, which causes pusher 800 to move toward tissue-contacting surface 750 (FIG. 13). Further movement of the driver 820 causes sequential ejection of the fasteners 760. Proximal movement of driver 820 causes retraction cam surface 826 to contact second cam surface 808 of pusher 800, which causes the pusher 800 to move away from tissue-contacting surface 750 (see FIG. 13). Further such movement of the driver 820 causes sequential retraction of the fasteners 760. Additionally, in the embodiment illustrated in FIG. 5, the driver 820 is rigidly attached to dynamic clamping member 240.

In use, actuation of movable handle 132 causes distal translation of dynamic clamping member 240, which causes distal translation of drivers 820. As drivers 820 advance distally, firing cam surfaces 824 of drivers 820 contact first cam surfaces 824 of pushers 800, which causes pushers 800 move toward tissue-contacting surface 750 of cartridge body 740. As shown in FIG. 13, pushers 800 sequentially move toward tissue-contacting surface 750 (i.e., the proximal-most pusher moves first, followed by the distally-adjacent pusher, etc.). Movement of pushers 800 toward tissue-contacting surface 750 causes corresponding fasteners 760 to be sequentially ejected from cartridge body 740. Here, after pushers 800 are elevated and within slots 822 of drivers 820, pushers 800 resist the force of corresponding biasing members 722, and thus prevent another fastener 760 from entering pockets 742 (i.e., the fasteners 760 remain in chambers 744). As the driver 820 is distally advancing and the fasteners 760 are being ejected from cartridge 710, a cutting element 242 (FIG. 14) of dynamic clamping member 240 cuts tissue between the jaw members 230.

After the driver 820 has been advanced a predetermined amount (e.g., corresponding to when all fasteners 760 have been ejected), a user may retract dynamic clamping member 240, and thus the driver 820. More than one driver 820 is contemplated herein. Retraction of driver or drivers 820 causes retracting cam surfaces 826 to contact second cam surfaces 808 of pushers 800, which causes pushers 800 to sequentially move away from tissue-contacting surface 750 of cartridge body 740. After pushers 800 have been moved away from tissue-contacting surface 750, pushers 800 no longer resist the force of corresponding biasing members 722, and thus biasing members 722 force another fastener 760 from chamber 744 into pocket 742.

Once drivers 820 have been retracted a predetermined amount (e.g., corresponding to when proximal-most fasteners 760 have been urged form chambers 744 into pockets 742), a user may repeat the process of advancing and retracting dynamic clamping member 240 and drivers 820 to eject another set of fasteners 760 without the need to replace cartridge channel 700 or cartridge assemblies 710. After all of the fasteners have been ejected from the cartridge assemblies, the plates 780 block the drivers from being advanced, and the clamping member 240 from being advanced, to prevent the firing of an empty cartridge. +

The illustrated embodiments illustrate three fasteners 760 in each pocket 742/chamber 744, but it is envisioned and within the scope of the present disclosure to include more or fewer fasteners 760 therein. It is also envisioned that at least one fastener 760 of cartridge assembly 710 is a different size from other fasteners 760. For example, it is envisioned that the inner row of fasteners (i.e., initially within pockets 742) includes fasteners having legs of a longest length, and that the outer row of fasteners includes fasteners having legs of a shortest length, or vice versa. Here, it is envisioned that the pushers 800 are sized accordingly.

The present disclosure also includes a method of firing a set of fasteners from a cartridge assembly, and then firing another set of fasteners from the same cartridge assembly without the need to remove and/or replace the cartridge assembly.

The present disclosure also includes embodiments having other types of handles than the illustrated embodiment. For example, the present disclosure also includes a powered (e.g., electrically-powered, battery-powered, etc.) handle.

While the above description contains many specifics, these specifics should not be construed as limitations on the scope of the present disclosure, but merely as illustrations of various embodiments thereof. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. 

The invention claimed is:
 1. A cartridge assembly for use with a surgical instrument, comprising: a cartridge housing having a plurality of flexible fingers; and a cartridge configured to be received at least partially within the cartridge housing, the cartridge including a tissue-contacting surface and a plurality of fasteners, the cartridge defining a plurality of pockets extending through the tissue-contacting surface, each one of the plurality of pockets configured to receive one of the plurality of fasteners, the cartridge having a plurality of chambers, each one of the plurality of chambers configured to receive at least one of the plurality of fasteners therein, each one of the plurality of chambers in communication with the respective one of the plurality of pockets, wherein each one of the plurality of flexible fingers urges the at least one of the plurality fasteners in the respective one of the plurality of chambers toward the respective one of the plurality of pockets.
 2. The cartridge assembly according to claim 1, wherein the plurality of flexible fingers are disposed on opposing sides of the cartridge housing.
 3. The cartridge assembly according to claim 2, wherein the plurality of flexible fingers on the opposing sides of the cartridge housing are biased toward each other.
 4. The cartridge assembly according to claim 1, wherein the cartridge further includes a plurality of pushers, each one of the plurality of pushers configured to eject the respective one of the plurality of fasteners through the respective one of the plurality of pockets.
 5. The cartridge assembly according to claim 4, further comprising a plurality of plates, each one of the plurality of plates operatively coupled to the respective one of the plurality of flexible fingers.
 6. The cartridge assembly according to claim 5, wherein each one of the plurality of plates is configured to inhibit actuation of the respective one of the plurality of pushers in the absence of the respective one of the plurality of fasteners in the respective one of the plurality of pockets.
 7. The cartridge assembly of claim 1, wherein the plurality of flexible fingers are leaf springs.
 8. A loading unit configured for engagement with a surgical instrument comprising: a proximal body portion defining a longitudinal axis; a tool assembly disposed in mechanical cooperation with the proximal body portion; and a cartridge assembly disposed in mechanical cooperation with the tool assembly, the cartridge assembly including: a cartridge housing having a plurality of flexible fingers; and a cartridge configured to be received at least partially within the cartridge housing, the cartridge including a tissue-contacting surface and a plurality of fasteners, the cartridge defining a plurality of pockets extending through the tissue-contacting surface, each one of the plurality of pockets configured to receive one of the plurality of fasteners, the cartridge having a plurality of chambers, each one of the plurality of chambers configured to receive at least one of the plurality of fasteners therein, each one of the plurality of chambers in communication with the respective one of the plurality of pockets, wherein each one of the plurality of flexible fingers urges the at least one of the plurality fasteners in the respective one of the plurality of chambers toward the respective one of the plurality of pockets.
 9. The loading unit according to claim 8, wherein the plurality of flexible fingers are disposed on opposing sides of the cartridge housing.
 10. The loading unit according to claim 9, wherein the plurality of flexible fingers on the opposing sides of the cartridge housing are biased toward each other.
 11. The loading unit according to claim 8, wherein the cartridge further includes a plurality of pushers, each one of the plurality of pushers configured to eject the respective one of the plurality of fasteners through the respective one of the plurality of pockets.
 12. The loading unit according to claim 11, further comprising a plurality of plates, each one of the plurality of plates operatively coupled to the respective one of the plurality of flexible fingers.
 13. The loading unit according to claim 12, wherein each one of the plurality of plates is configured to inhibit actuation of the respective one of the plurality of pushers in the absence of the one of the plurality of fasteners in the respective one of the plurality of pockets.
 14. The loading unit according to claim 11, further including a driver disposed in mechanical cooperation with the cartridge assembly, the driver configured to engage the plurality of pushers.
 15. The loading unit according to claim 14, wherein the driver is configured to sequentially engage the plurality of pushers.
 16. The loading unit according to claim 8, wherein the plurality of flexible fingers are leaf springs.
 17. The loading unit according to claim 8, wherein each one of the plurality of chambers is configured to receive three fasteners therein. 